| Author | Message | ||
     Oopezoo |
I posted this in the KV a few days ago, but I'm not sure things get found in there I picked this '98 S1 up a few weeks ago and have begun to get things sorted out on it. It has a Forcewinder intake and a 2" inlet Borla CF exhaust on it. So far I have rebuilt both braking systems, rejetted the carb, added turn signals (they were removed), and sorted out a few other odds and ends. It runs great.....its a little loud for me, but a hell of a lot of fun. On to my latest issue. I took it out for a nice long shakedown run before the weather went to shit, and basically the muffler fell off. The front muffler tab broke right were it is welded to the tube. To make matters worse, the PO had some shoddy hardware store bracket on the rear of the muffler that broke also. Luckily, the header pipes were wrapped, so the wrap actually prevented the muffler from falling completely off. I wired it back in place with some random roadside wire I found and limped home. So this morning I decided to rip the whole system off and see what I was dealing with. I pulled the muffler, removed the header, and then unwrapped it. Here is what I found By looking at the parts catalog, there is supposed to be a mounting tab here for a tie bar.  It looks like it had been ripped off at some point and the PO decided to put a small piece of metal over it (sitting on the floor), hose clamp it down, and then use the header wrap to cover the mess. The rest of the header looks to be in good shape besides the discoloring. On to the muffler. Front tab broken  Rear tab in tact.....luckily the hardware store strap was much weaker than the muffler tab  The rear muffler tab had that cheapy strap connected to a pretty nice beefy bracket. I don't know if its home made, or something that was bought. I've never seen one like it, but it looks too nice to be the PO's hand work. Its in good shape and sturdy enough that I would trust reusing it if needed. Some pics   OK, so on to what to do. The bike still has the old style L shaped front muffler mount, so I know I need to replace that with the Y shaped dogbone style before anything else. As far as what I have sitting here......do you think any of it is worth salvaging, or should I just cut my losses and start shopping for a complete new system? I'm not a skilled enough welder to tackle anything like this, but I do have guys at work that can. Is it worth the trouble to attempt to fabricate a fix on that header and/or muffler? If its all a lost cause.......is there any reason not to replace the current 2" header/muffler with a 2.5" setup if thats what I end up finding? I know I need an over the tube header, but I was curious if there were any other differences between the 2" and 2.5" systems on the early tubers? I've done a LOT of reading since this happened, so I know what to do to make sure it doesn't happen again. I guess I'm just checking if I would be wasting my time/money on trying to band-aid what I have. I don't need it to be perfect, I just don't want to start dealing with bigger issues down the road if I can't get it right (broken header bolts and such). Any direction would be greatly appreciated. | ||
| Steveford |
The only things I can offer is that looks like a V&H mount underneath the bike and I believe that there are two 2.5" over the frame headers - one which came stock on the 98 S1W/S3 and one for the race kit. Someone correct me if I'm wrong on the headers, please. If you can find a Buell race exhaust with the mounting hardware that's the route I'd go and then get the repacking material from American Sport Bike. | ||
| Charlies_s1 |
I would not spend the time with it, I know someone will come on here and say different. Yes that is a Vance and Hines rear bracket, I think I may have an extra can in good shape I could sell you that would bolt right up to it. Also I have a header pipe that came from St. Paul Harley that is painted black that is new that I could also provide. Don't know if you would be interested or not? Let me make sure and go out in the garage to check if the can is a 2" or a 2 1/2, Chuck. | ||
| Tombo |
That is the original 2" header with a Borla muffler. I had the same setup (sounds fantastic) and had my rear tab brake off. I replaced it with hoop bracket and it worked fine. Early headers are getting very hard to find and I would look into having it welded. That header tab was used on early bikes but eventually eliminated on later headers and does not exist on the race headers. One last thing to do, I would make sure the front exhaust hanger still has the rubber bushing (or is the newer style), if that Borla mount was hard mounted to the engine it would not last and will crack very quickly (that was the issue with my rear Borla mount. | ||
| Charlies_s1 |
Keith the can I have is 2" and looks good only has some scratches from my pit stand, I could send you pictures tomorrow of the header and the Vance and Hines can if you like? The header is new and I really don't know why they come painted black to be honest. You could have it ceramic coated or wrap it. Let me know. | ||
| Blks1l |
I know lots of people say you need to update the forward hanger but with the lighter aftermarket mufflers I dont think that is big of a necessity. You can fix what you have there easy enough, if done properly stronger than original. | ||
| Blks1l |
The black header was for the M 2's. | ||
| Bluzm2 |
Steve, If memory serves, there were actually 3 headers, the 2" for the regular S1, the 2.5" for the S1W and the 2.5" race header. The race header wrapped under the motor and a straight shot into the muffler like the later race headers. | ||
| Charlies_s1 |
Had to check their site but they list them for both bikes. (Message edited by Charlies_s1 on December 08, 2014) | ||
| Oopezoo |
Thanks for the info guys. Sounds like I had the correct thought process on what I have sitting here. I may attempt a repair on the muffler, but I'm pretty sure that header will end up in the scrap heap. Also, for the confirmation on that rear mounting bracket. I thought it might have been a V&H due to seeing some pics of their muffler, but I wasn't sure. Chuck.....thanks for the offer. Let me see what I can figure out with what I have and I will let you know. I think I can save the muffler by grinding off what is left of that front tab, and replacing it with a standard 2" wrap around style band clamp. I may be interested in the header though. If you want to shoot me an email with a pic and what you want for it (oopezoo AT aol DOT com). Shipping would be to 17368. I have a line on a 2" silver ceramic coated header that will fit as well, but I'm waiting to hear back from the owner on a price. | ||
| Dannybuell |
I'll take that header if you are going to scrap it! I have a souvenir that would make a great donor for your missing piece. Is the header Stainless steel? | ||
| Oopezoo |
I could be wrong, but I don't think it is stainless steel. If it is, its not very good quality SS. The pipe has a good amount of discoloration and surface rust on it. Let me figure out what I'm doing to get this thing back on the road and then I'll see what I have left over to get rid of. I won't toss anything out without trying to find it a new home first. | ||
| Hootowl |
It is stainless. Stainless steel will stain (it's a bit of a misnomer), just not as easily as other alloys of steel. When you get something that hot, all sorts of things can happen. It'll polish right up though. | ||
| Oopezoo |
Yup....I'm wrong. Now I'm really curious if I can salvage it. I'll have to ask the guys at work if they have the ability to weld SS tubing that thin without blowing holes in it. It also looks like St. Paul HD still has some "blemished" headers in stock that would fit. Are these painted SS, or just painted mild steel? http://www.ebay.com/itm/NEW-Blem-Buell-Header-96-9 7-S1-97-98-M2-with-2-Collector-65298-97Y-26-/28151 3710190?pt=Motorcycles_Parts_Accessories&hash=item 418b86526e | ||
| D_adams |
It's not that thin, it's easy enough to weld on. Just make sure it's cleaned and purged on the inside during welding, your guys at work should know this already, if they don't, have someone that knows what they're doing have at it instead. | ||
| D_adams |
And for the price on those blemished headers, I'd grab a set. Strip and re-coat them in ceramic, new headers and done. Well worth the money. | ||
| Jolly |
I have a drummer on my 96s1 with a ceramic coated header and I am very happy with the performance and quality. If you are looking for options I can highly recommend the Drummer. I also have a Borla on my 98s1w and a spare Borla for my s2... So I'm familiar with the Borlas, but if you are looking for a replacement I really do recommend Drummer. | ||
| Oopezoo |
I showed my buddy at work the pics I posted above and he said it should be no problem to patch that up and make it usable. I won't have the mounting tab there, but I can always rig up my own exhaust band clamp and a make a tie bar. I'm going to drag it into work tomorrow for him to give it a whirl. | ||
| Ratbuell |
David (Jolly) - you have an S2 borla? Hmmm...like, for a stock S2 header? | ||
| Jolly |
Yeah I think it is for a stock header, have not yet mocked it up but it looks like it though! want photos? | ||
| Oopezoo |
So it turns out that the patch panel the PO had on the header was not SS. Luckily I had a few pieces of a stock SS header from an old BMW car sitting under my work bench. I sectioned a piece out, cleaned it up, and then cut/formed it to the S1 header. My buddy at work went at this morning with the TIG welder and it looks like I have a functional exhaust again.   I still need to figure out what I'm going to use for an exhaust bracket and tie bar, but that should be the "easy" part. | ||
| Brother_in_buells |
Keith, Maybe this could work for you!? http://www.badweatherbikers.com/buell/messages/476 23/705131.html?1364789509 | ||
| Al_lighton |
Note that those blem headers are NOT stainless like the other headers from those years would be. They are mild steel. By the time you factor in strip and recoat costs, they might not be as good a deal as they first appear. Unless of course you were going to coat them in another color (i.e., silver, which works better) regardless. The equivalent header in stainless is still available, but not for long: http://americansportbike.com/newdir/Item/17428 Al |
